Method of reducing corrosion and corrosion byproduct deposition in a crude unit

ABSTRACT

A method of optimizing system parameters in a crude unit to reduce corrosion and corrosion byproduct deposition in the crude unit is disclosed and claimed. The method includes measuring or predicting properties associated with the system parameters and using an automated controller to analyze the properties to cause adjustments in the chemical program to optimize the system parameters. Adjusting the system parameters effectively controls corrosion in the crude unit by reducing the corrosiveness of a fluid in the process stream and/or by protecting the system from a potentially corrosive substance. System parameter sensing probes are arranged at one or more locations in the process stream to allow accurate monitoring of the system parameters in the crude unit.

TECHNICAL FIELD

This invention relates generally to methods of reducing corrosion in acrude unit. More specifically, the invention relates to methods ofoptimizing system parameters in a process stream of a crude unit toreduce corrosion in the crude unit. The invention has particularrelevance to sampling dew point water and accumulator boot water tomeasure system parameters and respond to such measurements to reducecorrosion and/or corrosion byproduct deposition in the crude unit.

BACKGROUND

In a crude oil refinery, generally the oil is pumped from a storage tankto a crude unit for processing. The crude unit cleans the oil throughwater washing in a desalter and then splits the oil into fractions in anatmospheric distillation tower. These fractions are pumped to variousprocessing units downstream of the crude unit (e.g., coker, catalyticcracker, hydrotreater etc.). Though corrosion and corrosion byproductdeposition (the latter sometimes referred to herein as fouling) occur inmany areas of a crude unit, the most severe corrosion and foulingtypically take place in the overhead condensing system of theatmospheric distillation tower.

Refinery crude unit processing has becoming increasingly difficult inrecent years and is predicted to become even more challenging andcomplex for several reasons. For example, significant increases in crudeoil prices have caused refiners to aggressively pursue “opportunity” or“challenging” crudes that are obtainable at discounted prices. The lowerprice is linked to a crude property such as high acid or high solidscontent that makes it less desirable than the light, sweet benchmarkcrudes.

Refiners switch crude slates more frequently than in the past due tominimum on-hand crude oil inventory combined with increased crude oilvariety. A crude slate switch typically upsets the steady statecondition of a crude unit for up to several hours. Generally, abouteighty percent of the corrosion and fouling occurs during these switchesor disruptions, which normally last about twenty percent of the time. Iffouling and corrosion issues are severe enough, the refiner willdiscontinue processing the crude oil or blend of crudes causing theproblem. However, these challenging crudes are available to the refinerat a discount thus making them more profitable. Discontinuing suchproblematic crudes is accordingly not a very popular option.

In efforts to reduce corrosion, a crude unit may be serviced two orthree times per week, or in some cases daily. Daily service at bestprovides a snap shot view of a dynamic crude unit system. Crude typeand/or raw crude storage tanks are switched several times per week,sometimes daily. The contents of each tank are different from theothers, so each switch causes a change of feed quality to the crudeunit, many times upsetting the steady state status and causingdisruptions in the system. Preheating, desalting, and distillingoperations shift with the new crude, sending products and/or effluentwater sources off specification. Many adjustments over several hours (insome cases days) normally take place to return the crude unit to steadystate operation.

The most common current industry practice to control such disruptionsand optimize crude unit operation is to provide enough manpower andman-hours. For instance, each crude unit may have an operating crew fromthree to ten people, depending on size and complexity of the unit. Thiscrew may spend their day gathering various samples for wet chemistry labtesting, and measuring and making adjustments for temperature and flowto keep the unit running within specification. Such practice istypically geared towards keeping the unit operating properly withrespect to fractionation quality cut points and end points, with minimalattention being paid to a specialty chemical corrosion control program.If a disruption is severe, changes may be made to the process chemicalsand/or changes in levels, flows, or temperatures may be recommendedaround the crude unit to keep the dynamic system in as optimum acondition as possible.

Attempts to compensate for periodic or sometimes prolonged lack of humaninvolvement include installing online pH meters on atmosphericdistillation towers overhead accumulator water boots; however, due to ahigh rate of fouling of the pH sensor only a small percentage of thesemeters operate correctly for any length of time. Online instrumentation,such as pH meters, requires routine maintenance and calibration.Moreover, online pH merely tracks the pH and sends an alarm to theoperator when the pH is outside the control limits. Often, poorlycalibrated and/or fouled pH meters cause frequent alarms. This frequencytends to minimize the effectiveness of the alarm system.

Due to the lack of industry success with online pH metering and othermonitoring efforts refiners have not pursued more exotic and effectiveonline instrumentation for process chemical programs. There thus existsan ongoing need for more sophisticated and effective online and/orautomatic methods for monitoring parameters and reducing corrosion incrude units.

SUMMARY

This invention accordingly provides methods to generate reliable crudeunit data in a feedback, feed-forward, or predictive loop(s) to makereal-time adjustments to process stream treatments thus reducingcorrosion and corrosion byproduct deposition (sometimes referred toherein as fouling). In a preferred aspect, the invention is implementedto provide continuous or intermittent feedback, feed-forward, orpredictive information to process chemical injection pumps to makereal-time adjustments. The invention incorporates programming logic toconvert analyzer signals to pump adjustment logic and, in a preferredembodiment, controls one or each of a plurality of chemical injectionswith a unique basis. Examples include neutralizer injection based on pH,chloride, or acid content; caustic agent injection based on pH,chloride, or acid content; and filming inhibitor injection based on ironconcentration or corrosion rate.

It is also envisioned that the invention will manage the readings fromexisting electrical resistance corrosion probes, linear polarizationprobes, and/or other techniques for measuring metal loss. These readingswill be programmed through a Programming Logic Controller (PLC) topossibly override or modify the other chemical inputs and change pumprates. Moreover, because the crude unit atmospheric distillation toweroverhead heat exchanger system suffers frequent and costly issues withcorrosion, the invention focuses on that part of the crude unit.However, the invention has utility on many other units in the refinery.

In an aspect, the invention includes a method of optimizing a systemparameter in a process stream of a crude unit to reduce corrosion in thecrude unit. A property associated with the system parameter is measuredand/or predicted at or more points in the crude unit and is convertedinto an input electrical signal capable of being transmitted to acontroller. In turn, the controller is operable to receive thetransmitted input electrical signal, convert the received electricalsignal into an input numerical value, analyze the input numerical value,generate an output numerical value, convert the output numerical valueinto an output electrical signal, and transmit the output electricalsignal. An optimum corrosion-reducing range for the input numericalvalue is determined and if the input numerical value is outside of theoptimum range, the transmitted output electrical signal causes a changein an influx of a composition into the process stream. The compositionis capable of adjusting the property associated with the systemparameter in a manner to bring the input numerical value within theoptimum range. In an embodiment, an influx of one or more differentcompositions into the process stream are collectively and/orindividually capable of adjusting the property(ies) associated with thesystem parameter(s). The method is optionally repeated for a pluralityof different system parameters, where each different system parameterhas a unique associated property.

In another aspect, the invention includes a system for optimizing asystem parameter in a process stream of a crude unit to reduce corrosionin the crude unit. The system comprises a sensing device operable tosense and/or predict a property associated with the system parameter andconvert the property into an input electrical signal capable of beingtransmitted. A transmitter transmits the input electrical signal to acontroller. The controller is operable to receive the transmitted inputelectrical signal, convert the received input electrical signal into aninput numerical value, analyze the input numerical value to determine ifthe input numerical value is in an optimum range, generate an outputnumerical value, convert the output numerical value into an outputelectrical signal, and transmit the output electrical signal. A receiverreceives the output electrical signal and is operable to cause a changein an influx rate of a composition into the process stream if the outputnumerical value is not within the optimum range, wherein the compositionis capable of adjusting the property associated with the systemparameter.

In an embodiment, one or more of the described controller functions maybe imparted to one or more data capturing devices.

It is an advantage of the invention to provide continuous control of oneor more key process corrosion control chemicals, an improvement over thecurrent practice of manual, highly variable frequency optimization.

Another advantage of the invention is to provide a method to achieveoptimum efficiency through reduced corrosion and fouling, minimizing theamount of product that does not meet specification, and reducing theamount of slop oil processing.

It is another advantage of the invention to provide an automated processto efficiently minimize disruptions and the resulting corrosion andfouling caused by a switch between various types of crude slates,including challenging crude, and minimize corrosion, disruptions, anddowntime during such switching.

It is a further advantage of the invention to provide continuous data tomeasure the magnitude of a disruption and to more precisely identify theroot cause of a disruption, including determining the concentration ofcorrosion byproduct(s) formed in the system due to a spike in corrosionduring a disruption.

An additional advantage of the invention is to provide a method ofoptimizing system efficiency when crude slates are changed by quicklystabilizing system operating parameters.

It is yet another advantage of the invention to provide data leading toa level of corrosion control that will help prevent expensive metallurgyupgrades in crude refining systems in order to process acidic crudes.

Additional features and advantages are described herein, and will beapparent from, the following Detailed Description, Examples, andFigures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of an embodiment of the invention showingvarious crude unit components and exemplary points at which systemparameters are measured.

FIG. 2 shows a flowchart of a preferred embodiment of controlling theintroduction of neutralizer(s) into the system based upon measured pH.

FIG. 3 illustrates an embodiment of the invention for controlling theintroduction of caustic agent(s) into the system driven by the chlorideion concentration signal.

FIG. 4 illustrates an embodiment of the invention for controlling theintroduction of filming inhibitors into the system driven by the ironion concentration signal.

FIG. 5 depicts an embodiment of the invention for controlling theoverride of the introduction of neutralizer(s), caustic agent(s), andfilming inhibitors into the system driven by the corrosion rates derivedfrom one or more corrosion probes or other corrosion monitoring devicesat any point in the system.

FIG. 6 shows a number of spikes of chloride concentration above theupper control limit from actual data from a crude unit and demonstrateshow the method of the invention will be used to stabilize chloride ionconcentration when tied to corrective action.

FIG. 7 shows pH and chloride ion concentration values tracked over timein an actual crude unit and demonstrates how the method of the inventionwill be used to stabilize these values.

DETAILED DESCRIPTION

As one of the main components of a crude unit process, corrosion controlplays a vital role in maintaining system integrity. This inventionprovides a way to optimize the corrosion control component of the crudeunit through optimizing one or more system parameters in a processstream of the crude unit. This optimization includes measuringproperties associated with those parameters in the process stream.

The corrosion control program of the invention is designed to reducecorrosion of refinery processing equipment and subsequent fouling due todeposition of corrosion byproducts. A typical corrosion control programincludes components such as a neutralizing amine, a filming inhibitor, acaustic solution, etc. Such corrosion control chemicals aretraditionally injected into the system based upon measurements derivedfrom grab samples and analyzed in the lab or some flow indication on theunit. This invention provides an automated method of adjusting chemicalinjection into the system.

In a preferred embodiment, the method of the invention includes acontroller operable to receive and process information and provideinstructions to various components (e.g., chemical injection pumps). Theterm “controller” refers to a manual operator or an electronic devicehaving components such as a processor, memory device, digital storagemedium, cathode ray tube, liquid crystal display, plasma display, touchscreen, or other monitor, and/or other components. The controller ispreferably operable for integration with one or moreapplication-specific integrated circuits, programs, computer-executableinstructions or algorithms, one or more hard-wired devices, wirelessdevices, and/or one or more mechanical devices. Moreover, the controlleris operable to integrate the feedback, feed-forward, or predictiveloop(s) of the invention. Some or all of the controller system functionsmay be at a central location, such as a network server, forcommunication over a local area network, wide area network, wirelessnetwork, internet connection, microwave link, infrared link, and thelike. In addition, other components such as a signal conditioner orsystem monitor may be included to facilitate signal transmission andsignal-processing algorithms.

Preferably, the controller includes hierarchy logic to prioritize anymeasured or predicted properties associated with system parameters. Forexample, the controller may be programmed to prioritize system pH overchloride ion concentration or vice versa. It should be appreciated thatthe object of such hierarchy logic is to allow improved control over thesystem parameters and to avoid circular control loops.

In one embodiment, the method includes an automated controller. Inanother embodiment, the controller is manual or semi-manual. Forexample, where the crude refining process includes one or more datasetsreceived from a various sensors in the system, the controller may eitherautomatically determine which data points/datasets to further process oran operator may partially or fully make such a determination. A datasetfrom a crude unit, for instance, may include variables or systemparameters such as oxidation-reduction potential, pH, levels of certainchemicals or ions (e.g., determined empirically, automatically,fluorescently, electrochemically, calorimetrically, measured directly,calculated), temperature, pressure, process stream flow rate, dissolvedor suspended solids, etc. Such system parameters are typically measuredwith any type of suitable data capturing equipment, such as pH sensors,ion analyzers, temperature sensors, thermocouples, pressure sensors,corrosion probes, and/or any other suitable device or method. Datacapturing equipment is preferably in communication with the controllerand, according to alternative embodiments, may have advanced functions(including any part of the control algorithms described herein) impartedby the controller.

Data transmission of measured parameters or signals to chemical pumps,alarms, or other system components is accomplished using any suitabledevice, such as a wired or wireless network, cable, digital subscriberline, internet, etc. Any suitable interface standard(s), such as anethernet interface, wireless interface (e.g., IEEE 802.11a/b/g/x,802.16, Bluetooth, optical, infrared, radiofrequency, etc.), universalserial bus, telephone network, the like, and combinations of suchinterfaces/connections may be used. As used herein, the term “network”encompasses all of these data transmission methods. Any of the describeddevices (e.g., plant archiving system, data analysis station, datacapture device, process station, etc.) may be connected to one anotherusing the above-described or other suitable interface or connection.

In an embodiment, system parameter information is received from thesystem and archived. In another embodiment, system parameter informationis processed according to a timetable or schedule. In a furtherembodiment, system parameter information is immediately processed inreal-time/substantially real-time. Such real-time reception may include,for example, “streaming data” over a computer network.

Referring now to the Figures, FIG. 1 depicts a diagram of a preferredembodiment of the invention. It should be appreciated that theparticular configuration of the crude unit is not critical to theinvention and FIG. 1 illustrates one possible configuration. FIG. 1shows a typical atmospheric distillation tower system 100 of a crudeunit that includes overhead heat exchanger bank 102, accumulator 104,distillation tower 106, and pumparound heat exchangers 108 a and 108 b.In this embodiment, a dew point water sample is obtained at theindicated point and a sample of accumulator boot water is obtained atthe indicated points on FIG. 1. These samples are measured and analyzedfor the system parameters of pH, chloride ion concentration, and ironion concentration.

FIG. 1 shows values of 5.8 for pH and 93 ppm for chloride ionconcentration at the dew point water sample point and values of 6.7 and10, respectively, at the accumulator boot sample point. The measurementdifferences at these two sample points require a corresponding algorithmto adjust chemical injection. The preferred location in the crude unitfor determining pH and chloride ion concentration is a dew point watersample, usually derived from the overhead heat exchangers of thedistillation tower. Another advantage of determining pH from the dewpoint water is that the pH probe encounters lower levels of contaminantsand fewer solid particles and oil droplets resulting in less frequentfouling. The term “dew point” refers to the point of initialcondensation of steam to water or the temperature at which a phase ofliquid water separates from the water vapors and liquid hydrocarbons andbegins to form liquid water as the vapors cool. Though possible to usethe accumulator water boot to measure pH and chloride ion level, a levelof accuracy is usually sacrificed because data is diluted or masked bythe full volume of steam and weak acids and bases that have condenseddownstream of the water dew point.

In a preferred embodiment, dew point water is analyzed for pH andchloride. It is advantageous to analyze dew point water rather thanoverhead accumulator water for pH and chloride because the dew pointwater is typically cleaner and provides a faster response with moreaccurate measurement of these system parameters. Testing usually revealsa dramatic difference between water samples from these two locations. Onmany units, the dew point chloride concentration may be several hundredppm, while a similar sample taken from overhead accumulator water may,at the same time, be from 10 to 50 ppm. For example, dew point water mayhave a pH of 5.8 and a chloride ion concentration of 93 ppm; whereas,the accumulator boot water of the same unit may have values of 6.7 and10, respectively.

Likewise, it is possible to measure iron (or other metals, such ascopper, molybdenum, nickel, zinc) ion concentration from the dew pointwater. The preferred location for determining iron or other metal ionconcentration is at the accumulator water boot because these ionsindicate corrosion has taken place and metal has been removed from aninternal component in the system upstream of the sample point.

It should be appreciated that any suitable method may be used forobtaining the dew point water sample. For example, devices for obtainingthe dew point water sample are disclosed in U.S. Pat. Nos. 4,335,072,titled “Overhead Corrosion Simulator” and 5,425,267, titled “CorrosionSimulator and Method for Simulating Corrosion Activity of a ProcessStream,” each of which is incorporated herein by reference in itsentirety.

In alternative embodiments, different fluid or system parameters orother constituents present in the system could be measured and/oranalyzed. Representative measured parameters or constituents include pH;chloride ion; other strong and weak acids, such as sulfuric, sulfurous,thiosulfurous, carbon dioxide, hydrogen sulfide; organic acids; ammonia;various amines; and liquid or solid deposits. Various methods ofmeasuring such parameters are contemplated and the invention is notlimited to one particular method. Representative methods include, butare not limited to those disclosed in U.S. Pat. Nos. 5,326,482, titled“On-Line Acid Monitor and Neutralizer Feed Control of the Overhead Waterin Oil Refineries”; 5,324,665, titled “On-Line Method for MonitoringChloride Levels in a Fluid Stream”; 5,302,253, titled “On-Line AcidMonitor and Neutralizer Feed Control of the Overhead Water in OilRefineries,” each of which is incorporated herein by reference in itsentirety.

In response to the measured system parameters, FIG. 1 shows exemplaryintroduction points for neutralizers, filming inhibitors (sometimesreferred to herein as “filmers”), and caustic agents. These points arelabeled “Neutralizer based on acid or pH,” “Filmer based on iron,” and“Caustic based on chloride.” It should be appreciated that suchchemicals may be added at any suitable location in the system, but arepreferably added at the indicated point on FIG. 1. In this embodiment,neutralizer and filming inhibitor is added upstream of overhead heatexchanger bank 102 and caustic agent is added into the crude oil chargeof atmospheric distillation tower system 100. According to a preferredembodiment, introduction of such chemicals into the system are adjustedcontinuously. In other embodiments, chemical introduction is adjustedintermittently or in relation to a schedule as determined for eachindividual system.

Neutralizer(s), caustic agent(s), and filming inhibitor(s) may beintroduced to the system using any suitable type of chemical feed pump.Most commonly, positive displacement injection pumps are used poweredeither electrically or pneumatically. Continuous flow injection pumpsare sometimes used to ensure specialty chemicals are adequately andaccurately injected into the rapidly moving process stream. Though anysuitable pump or delivery system may be used, exemplary pumps andpumping methods include those disclosed in U.S. Pat. Nos. 5,066,199,titled “Method for Injecting Treatment Chemicals Using a Constant FlowPositive Displacement Pumping Apparatus” and 5,195,879, titled “ImprovedMethod for Injecting Treatment Chemicals Using a Constant Flow PositiveDisplacement Pumping Apparatus,” each incorporated herein by referencein its entirety.

Representative neutralizers include but are not limited to3-methoxypropylamine (MOPA) (CAS #5332-73-0), monoethanolamine (MEA)(CAS #141-43-5), N₃N-dimethylaminoethanol (DMA) (CAS #108-01-0), andmethoxyisopropylamine (MIOPA) (CAS #37143-54-7).

As a caustic agent, a dilute solution of sodium hydroxide is typicallyprepared in a 5 to 10% concentration (7.5 to 14° Baume) for ease ofhandling and to enhance distribution once injected into the crude oil,or desalter wash water, for example. Concentration may be adjustedaccording to ambient conditions, such as for freeze point in coldclimates.

Filming inhibitors or filmers used in conjunction with this invention ina crude unit corrosion control program are typically oil soluble blendsof amides and imidazolines. These compounds offer good corrosion controlwith minimal effects on the ability of the hydrocarbons in the system tocarry water.

FIG. 2 shows a flowchart of a preferred embodiment of controlling theintroduction of neutralizer(s) into the system based upon measured pH,labeled method 200. Box 202 represents the measuring device or analyzerthat provides information related to the pH of the dew point (oraccumulator) water. The analyzer (e.g., controller or operator)determines whether the pH is within an optimum range (5.8 to 6.0 in thisexample) as shown in box 204. If the pH is within the predeterminedoptimum range, the logic follows the “Yes” path and continues measuringand analyzing. If the pH is not within this range, the method includesdetermining whether the pH is below 5.8, as represented by box 206, orabove 6.0, as represented by box 208. If the pH is below 5.8, the methodincludes increasing the neutralizer pump by, for example, 5% or 10%, asshown by box 210. If the pH is above 6.0, the method includes decreasingthe neutralizer pump by, for example, 5% or 10%, as shown by box 212.

It should be appreciated that a suitable pH control or optimal rangeshould be determined for each individual system. The optimum range forone system may vary considerably from that for another system. It iswithin the concept of the invention to cover any possible optimum pHrange.

In different embodiments, changes in the neutralizer pump are limited infrequency. Preferably, adjustment limits are set at a maximum of 1 per15 min and sequential adjustments in the same direction should notexceed 8. For example, after 8 total adjustments or a change of 50% or100%, the pump could be suspended for an amount of time (e.g., 2 or 4hours) and alarm could be triggered. If such a situation is encountered,it is advantageous to trigger an alarm to alert an operator. Otherlimits, such as maximum pump output may also be implemented. It shouldbe appreciated that it is within the scope of the invention to cause anynumber of adjustments in any direction without limitation. Such limitsare applied as determined by the operator.

FIG. 3 illustrates an embodiment of the invention as method 300 forcontrolling the introduction of caustic agent(s) into the system drivenby the chloride ion concentration signal. Box 302 represents themeasuring device or analyzer that provides information related to thechloride ion concentration of the dew point water. The analyzer (e.g.,controller or operator) determines whether the chloride ionconcentration is within an optimum range (50 to 100 ppm in this example)as shown in box 304. If the chloride ion concentration is within thepredetermined optimum range, the logic follows the “Yes” path andcontinues measuring and analyzing. If the chloride ion concentration isnot within this range, the method includes determining whether thechloride ion concentration is below 50 ppm, as represented by box 306,or above 100 ppm, as represented by box 308. If the chloride ionconcentration is below 50 ppm, the method includes decreasing thecaustic pump by, for example, 20%, as shown by box 310. If the chlorideion concentration is above 100 ppm, the method includes increasing thecaustic pump by, for example, 20%, as shown by box 312.

It should be appreciated that a suitable or optimal chloride ionconcentration range should be determined for each individual system. Theoptimum range for one system may vary considerably from that for anothersystem. It is within the concept of the invention to cover any possibleoptimum chloride ion concentration range.

In different embodiments, changes in the caustic pump are limited infrequency. Preferably, adjustment limits are set at a maximum of 1 per30 min and sequential adjustments in the same direction should notexceed 4. For example, after 4 total adjustments or a change of 50% or100%, the pump could be suspended for an amount of time (e.g., 2 or 4hours) and alarm could be triggered. If such a situation is encountered,it is advantageous to trigger an alarm to alert an operator. Otherlimits, such as maximum pump output or maximum sodium contribution tothe system may also be implemented. It should be appreciated that it iswithin the scope of the invention to cause any number of adjustments inany direction without limitation. Such limits are applied as determinedby the operator.

FIG. 4 illustrates an embodiment of the invention as method 400 forcontrolling the introduction of filming inhibitors into the systemdriven by the iron ion concentration signal. Other metallurgy, such asmonel, titanium, brass, etc. may be used in some systems. In thesecases, rather than an iron ion concentration signal, the appropriatemetal ion (e.g., copper, nickel, zinc, etc.) concentration signal wouldbe detected and analyzed. Box 402 represents the measuring device oranalyzer that provides information related to the iron ion concentrationof the accumulator boot water. The analyzer (e.g., controller oroperator) determines whether the iron ion concentration is within anoptimum range (0.05 to 1.0 ppm in this example) as shown in box 404. Ifthe iron ion concentration is within the predetermined optimum range,the logic follows the “Yes” path and continues measuring and analyzing.If the iron ion concentration is not within this range, the methodincludes determining whether the iron ion concentration is below 0.05ppm, as represented by box 406, or above 1.0 ppm, as represented by box408. If the iron ion concentration is below 0.05 ppm, the methodincludes decreasing the filming inhibitor (i.e., filmer) pump by, forexample, 5%, as shown by box 410. If the iron ion concentration is above1.0 ppm, the method includes increasing the filmer pump by, for example,5%, as shown by box 412.

Metal ions commonly exist in two or more oxidation states. For example,iron exists in Fe²⁺ and Fe³⁺ as well being present in soluble states(ionic and fine particulate), insoluble states (i.e., filterable), etc.Analysis and control of metal ions includes measurement or prediction ofany combination (or all) of such permutations present in the system.

In different embodiments, changes in the filming inhibitor pump arelimited in frequency. Preferably, adjustment limits are set at a maximumof 1 per 30 min and sequential adjustments in the same direction shouldnot exceed 4. For example, after 4 total adjustments or a change of 50%or 100%, the pump could be suspended for an amount of time (e.g., 2 or 4hours) and alarm could be triggered. If such a situation is encountered,it is advantageous to trigger an alarm to alert an operator. Otherlimits, such as maximum pump output may also be implemented. It shouldbe appreciated that it is within the scope of the invention to cause anynumber of adjustments in any direction without limitation. Such limitsare applied as determined by the operator.

FIG. 5 depicts an embodiment of the invention as method 500 forcontrolling the override of the introduction of neutralizer(s), causticagent(s), and filmers into the system driven by the corrosion ratesderived from one or more corrosion probes or other corrosion ratesensing device at any point in the system. Most crude units useelectrical resistance-type corrosion probes located at the inlet and/orthe outlet of the overhead heat exchangers. Although any type ofcorrosion-sensing device is contemplated, the above-mentioned type ispreferred.

Box 502 represents the one or more corrosion probes that provideinformation related to the corrosion rates in the system. The analyzer(e.g., controller or operator) determines whether the corrosion rate isgreater than a predetermined rate (25 mpy in this example) as shown inbox 504. The actionable corrosion rate is typically determined on acase-by-case basis by a skilled artisan and is dependent on a multitudeof system factors. If the corrosion rate is less than a predeterminedacceptable rate, the logic follows the “No” path and continues measuringand analyzing. If the corrosion rate is above the predeterminedacceptable rate, the method includes overriding all other programmingand triggering an alarm, as shown by box 506. In alternativeembodiments, rather than an override other programming could be modifiedas determined by an operator or controller. In this example, theoverride includes increasing the neutralizer, caustic agent, and filmerpump rates by, for example 20%, as shown by box 508. In otherembodiments, the pump rates are changed individually as determined by anoperator or controller.

Although the corrosion probes (e.g., electrical resistance corrosionprobes, linear polarization probes, and/or any other suitable method fordetermining metal loss) may be placed at any convenient location in thesystem, preferably they are placed in historically reliable locations inthe system. In addition, if, for example, 2 overrides are activated overa 12 hr period, a reliability check is typically initiated to ensurethat the corrosion probes are operating properly. If such a situation isencountered, it is advantageous to trigger an alarm to alert anoperator. Other limits, such as maximum pump output may also beimplemented. It should be appreciated that it is within the scope of theinvention to cause any number of adjustments in any direction withoutlimitation. Such limits are applied as determined by the operator.

The foregoing may be better understood by reference to the followingexamples, which are intended for illustrative purposes and are notintended to limit the scope of the invention.

EXAMPLE 1

An exemplary embodiment of the invention would consist of a cluster ofon-line analyzers in an explosion-proof box receiving a sample of waterfrom a dew point water-sampling device. Data generated by theseanalyzers would be appropriately conditioned to send a control signal tovarious process chemical injection pumps. A Programmable LogicController (PLC) programmed by a skilled artisan would convert the rawdata into pump control signals. A typical system would include one ormore of the following components: chloride analyzer; iron analyzer;corrosion rate monitoring device; conductivity; pH meter; dew pointwater sample device; Class I, Div II explosion proof enclosure; PLCcapable of multiple inputs/outputs; logic programming to convertchloride, pH, and iron data into pump speed control; and wireless orhard-wired connections from PLC to pumps.

EXAMPLE 2

This instant invention would provide improvement in control for each ofthree test parameters of chloride ion concentration, pH, and iron ionconcentration. Of these three, chloride is usually the most damaging ifnot properly controlled. The graph in FIG. 6 demonstrates how theinvention would be capable of improving the control of chloride ionconcentration (the dotted line indicates optimum concentration). Asimilar concept of better control through the method of the inventionwill apply to pH, iron ion concentration, and other system parametersultimately resulting in corrosion rates reduced from previous levels andextending equipment run length.

FIG. 6 shows a number of spikes of chloride concentration above theupper control limit from actual data from a crude unit. Chloride spikesare damaging to equipment and an ex post facto examination of the datawill reveal increased corrosion and fouling during these episodes. Suchspikes are more frequent and damaging when the crude slate is switchedto a challenging or opportunity crude. Increased chloride ionconcentration usually occurs with a concomitant increase in corrosion ofthe processing equipment and subsequent fouling due to deposition ofcorrosion byproducts. The section of the graph in FIG. 6 labeled“Implement Control” demonstrates how the method of the invention wouldbe used to stabilize chloride ion concentration when more frequent datais available to minimize (or eliminate) disruptions.

EXAMPLE 3

The graph of FIG. 7 illustrates pH and chloride ion concentration valuestracked over time for an actual crude unit (the dotted lines indicateoptimum concentrations). It can be seen that a drop in the pH valueusually accompanies upward spikes for chloride ion concentration. Suchdrops in pH typically result in increased corrosion and subsequentfouling (due to corrosion byproducts) of the heat exchanging equipment.The section of the graph labeled “Implement Control” demonstrates howthe method of the invention would be used stabilize chloride ionconcentration and pH, thus reducing corrosion and fouling in the system.Smoothing variation of the incoming chloride values allows for tighterpH control and more stable and predictable chemical usage.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the invention and withoutdiminishing its intended advantages. It is therefore intended that suchchanges and modifications be covered by the appended claims.

1. A method of optimizing a system parameter in a process stream of acrude unit to reduce corrosion and/or corrosion byproduct deposition inthe crude unit, the method comprising: (a) measuring and/or predicting aproperty associated with the system parameter at one or more points inthe crude unit; (b) determining an optimum range associated with themeasured and/or predicted property; (c) if the measured and/or predictedproperty is outside of the optimum range associated with that property,causing a change in an influx of a composition into the process stream,the composition capable of adjusting the property associated with thesystem parameter in a manner to bring the measured and/or predictedproperty within said optimum range; and (d) optionally repeating steps(a) to (c) for a plurality of different system parameters, eachdifferent system parameter having a unique associated property.
 2. Themethod of claim 1, including: (i) converting the measured property intoan input electrical signal capable of being transmitted to a controllerand (ii) transmitting the input electrical signal to the controller. 3.The method of claim 2, including transmitting the input electricalsignal via a wireless interface.
 4. The method of claim 2, wherein thecontroller is operable to: (i) receive the transmitted input electricalsignal; (ii) convert the received electrical signal into an inputnumerical value; (iii) analyze the input numerical value: (iv) generatean output numerical value; (v) convert the output numerical value intoan output electrical signal; and (vi) transmit the output electricalsignal.
 5. The method of claim 4, including transmitting the outputelectrical signal via a wireless interface.
 6. The method of claim 4,wherein the controller is operable to: (i) analyze the input numericalvalue and (ii) determine if the input numerical value corresponds to theoptimum range associated with the measured property.
 7. The method ofclaim 6, wherein if the input numerical value does not correspond to theoptimum range, the transmitted output electrical signal causing thechange in the influx of the composition into the process stream, thecomposition capable of adjusting the property associated with the systemparameter in a manner to cause the input numerical value to correspondto the optimum input range.
 8. The method of claim 1, includingcontinuously or intermittently measuring and/or predicting the systemparameter.
 9. The method of claim 1, including monitoring the systemparameter in real time.
 10. The method of claim 1, including a pluralityof different compositions, wherein an influx of one or more of thedifferent compositions into the process stream are collectively and/orindividually capable of adjusting the property associated with thesystem parameter.
 11. The method of claim 1, wherein the plurality ofdifferent system parameters is selected from the group consisting of:pH, chloride ion concentration; iron ion concentration; non-iron metalion concentration; corrosion rate; and combinations thereof.
 12. Themethod of claim 11, wherein the crude unit has a plurality of componentsincluding an atmospheric tower with at least one heat exchanger, andwherein the pH and chloride ion concentration are derived from a dewpoint water sample and/or an accumulator boot water sample in the crudeunit and the iron ion concentration or the non-iron metal ionconcentration is derived from the accumulator boot water sample in thecrude unit.
 13. The method of claim 12, including obtaining the dewpoint water sample and/or the boot water sample with an online,optionally automated, sampling device.
 14. The method of claim 1,wherein the optimum range is user-defined.
 15. The method of claim 1,including operating the method continuously, automatically, and onlineor on a batch basis.
 16. The method of claim 1, including operating themethod either simultaneously or sequentially for at least two of thedifferent system parameters.
 17. The method of claim 1, includingoperating the method over a network.
 18. A digital storage medium havingcomputer-executable instructions stored thereon, the instructionsoperable to execute the method of claim
 1. 19. A system for optimizing asystem parameter in a process stream of a crude unit to reduce corrosionand/or corrosion byproduct deposition in the crude unit, the systemcomprising: (a) a sensing device operable to sense and/or predict aproperty associated with the system parameter and convert the propertyinto an input electrical signal capable of being transmitted; (b) atransmitter operable to transmit the input electrical signal (c) acontroller operable to receive the transmitted input electrical signal,convert the received input electrical signal into an input numericalvalue, analyze the input numerical value, determine if the analyzedvalue is within an optimum range, generate an output numerical valuebased upon the analyzed value, convert the output numerical value intoan output electrical signal, and transmit the output electrical signal;and (d) a receiver operable to receive the output electrical signal andcause a change in an influx rate of a composition into the processstream if the output numerical signal is not within the optimum range,wherein the composition is capable of adjusting the property associatedwith the system parameter.